Stacked electrical connector with terminal assurance mechanism

Abstract

A stacked electrical connector formed by mating an upper and a lower housing having rows of cavities containing terminals is disclosed. The upper and lower housings have primary terminal assurance provided by lances integrally formed into the housings. A secondary terminal assurance system is provided to further secure the terminals within the housings. In one embodiment, secondary terminal assurance is to terminals in the upper housing by lower housing protrusions and to terminals in the lower housing by a hinge. In another embodiment, secondary terminal assurance is provided to terminals in the upper and lower housing by upper and lower protrusions of a lock plate.

1. An electrical connector, comprising:
 an upper housing comprising cavities configured to receive electrical terminals and upper housing lances integrally formed into the upper housing for providing primary terminal assurance to the terminals received in the cavities in the upper housing; 
 a lower housing configured to be mated to the upper housing to form the electrical connector, the lower housing comprising cavities configured to receive electrical terminals and lower housing lances integrally formed into the lower housing for providing primary terminal assurance to terminals received in the lower housing; and 
 a secondary terminal assurance system configured to provide secondary terminal assurance to terminals received in the lower housing; 
 wherein the secondary terminal assurance system comprises a lock plate; 
 the lock plate is prevented from being removed from the lower housing when terminals are inserted into the lower housing. 
 
     
     
       2. The connector of  claim 1 , wherein the lock plate comprises a plurality of first protrusions that provide the secondary terminal assurance to terminals received in the lower housing when the lock plate is inserted into the lower housing. 
     
     
       3. The connector of  claim 1 , wherein the lock plate comprises a plurality of second protrusions that provide secondary terminal assurance to terminals received in the upper housing when the lock plate is inserted into the lower housing and the lower housing and upper housing are mated. 
     
     
       4. The connector of  claim 1 , wherein the lock plate comprises tabs that secure the lock plate into the lower housing when fully inserted. 
     
     
       5. The connector of  claim 1 , wherein the lock plate prevents mating the upper housing to the lower housing if a terminal is not fully inserted in the upper housing. 
     
     
       6. The connector of  claim 1 , wherein the lock plate is detachable from the lower housing. 
     
     
       7. The connector of  claim 1 , wherein the lock plate is attached to the lower housing. 
     
     
       8. A method of assembling an electrical connector comprising:
 providing an upper housing comprising cavities configured to receive and secure electrical terminals and upper housing lances configured to provide primary terminal assurance to the terminals received in the cavities in the upper housing; 
 providing a lower housing configured to mate with the upper housing to form the electrical connector, the lower housing comprising cavities configured to receive and secure electrical terminals and lower housing lances configured to provide primary terminal assurance to terminals received in the lower housing; 
 providing a secondary terminal assurance system configured to provide secondary terminal assurance to terminals received in the upper and lower housings; and 
 mating the upper and lower housings to form the electrical connector; 
 wherein the secondary terminal assurance system is a lock plate. 
 
     
     
       9. The connector of  claim 1 , wherein the upper lances and the lower lances secure terminals received in the upper housing and the lower housings, respectively, from moving. 
     
     
       10. The connector of  claim 8 , wherein the lock plate is configured so terminals can be loaded into the cavities of the upper housing and the lower housing when the lock plate is partially inserted into the lower housing. 
     
     
       11. The method of  claim 8 , wherein the lock plate is configured so terminals can be loaded into the cavities of the upper housing and the lower housing when the lock plate is partially inserted into the lower housing. 
     
     
       12. The method of  claim 8 , wherein the lock plate comprises a plurality of first protrusions that provide the secondary terminal assurance to terminals received in the lower housing when the lock plate is inserted into the lower housing. 
     
     
       13. The method of  claim 8 , wherein the lock plate comprises a plurality of second protrusions that provide secondary terminal assurance to terminals received in the upper housing when the lock plate is inserted into the lower housing and the lower housing and upper housing are mated. 
     
     
       14. The method of  claim 8 , wherein the lock plate comprises tabs that secure the lock plate into the lower housing when fully inserted. 
     
     
       15. The method of  claim 8 , wherein the lock plate prevents mating the upper housing to the lower housing if a terminal is not fully inserted in the upper housing. 
     
     
       16. The method of  claim 8 , wherein the lock plate is detachable from the lower housing. 
     
     
       17. The method of  claim 8 , wherein the lock plate is prevented from being removed from the lower housing when terminals are inserted into the lower housing. 
     
     
       18. The method of  claim 8 , wherein the upper lances and the lower lances secure terminals received in the upper housing and the lower housings, respectively, from moving.